Continuous Vacuum Chamber for Package Gas Evacuation
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Solution Overview
Problem
Existing packaging systems face challenges in efficiently evacuating gas from packages of varying sizes due to limitations in vacuum chamber size and complexity, leading to increased costs and processing times, and difficulty in maintaining reliability and durability.
Innovation Solution
A packaging process utilizing a continuous vacuum system with a fixed-gap vacuum chamber, where the package is moved relative to the chamber to create an internal vacuum pressure lower than ambient, allowing gas aspiration from both inside the package and the atmosphere, and using guide belts to shape the film and form channels for efficient evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vacuum chamber is designed to house entire products for evacuation, then evacuation function is provided, but the complexity and cost of equipment increases due to many components required
Solution Approach 1:
The vacuum chamber is divided into a fixed stationary base and a movable cover that can be opened and closed. This segmentation allows the package to be evacuated through a defined path while maintaining vacuum integrity, reducing the complexity of sealing mechanisms compared to fully enclosed chambers.
Solution Approach 2:
The vacuum chamber cover is made movable rather than fixed, allowing dynamic opening for package insertion and closing for evacuation. This dynamic design eliminates the need for complex fixed sealing mechanisms and enables continuous processing.
2Volume of moving object
If the vacuum chamber size is increased to accommodate larger products, then product size capability is improved, but processing time increases due to vacuumization of larger chambers
Solution Approach 1:
The package open end is divided into three portions (terminal, intermediate, non-terminal) with only the terminal portion inside the vacuum chamber during evacuation. This segmentation allows efficient evacuation of large packages without requiring large vacuum chambers.
Solution Approach 2:
The package is oriented horizontally with the open end extending perpendicular to the vacuum chamber opening, allowing the package to extend outside the chamber. This dimensional arrangement enables evacuation of large packages through a small chamber opening.
3Reliability
If sealing bars are used to create seals, then sealing function is provided, but the sealing bars must be stationary relative to the package requiring complex synchronization with conveyor movement
Solution Approach 1:
Instead of moving the sealing bars with the package, the sealing bars remain stationary and the package moves through them. This inversion eliminates the need for complex synchronization mechanisms while maintaining reliable sealing.
Solution Approach 2:
The sealing function is achieved through stationary sealing bars that create seals as packages pass by, rather than requiring the sealing mechanism to follow and copy the package movement exactly.
4Productivity
If sealing rolls are used to maintain continuous motion, then continuous processing is improved, but the open ends of packages must be fed through sealing rolls requiring lateral positioning
Solution Approach 1:
The package open end is positioned laterally on the side of the conveyor perpendicular to the main movement direction, allowing it to be fed through sealing rolls without complex synchronization. This dimensional repositioning simplifies the feeding mechanism.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables efficient evacuation of gas from packages of various sizes in a continuous and serial manner, reducing complexity and processing time, while maintaining cost-effectiveness and adaptability for different product sizes and shapes.
Implementation Method 1
creating, within the vacuum chamber, an internal vacuum pressure that is lower than an ambient pressure outside the vacuum chamber
Implementation Method 2
allowing gas aspiration from both inside the package and the atmosphere
Data Source
AI summary
A device (1) for evacuating gas from a package (50) in a packaging apparatus, the package (50) having an open end (55), the open end (55) having a terminal portion (54), a non-terminal portion (52), and an intermediate portion (53) located between the terminal portion (54) and the non-terminal portion (52) of the open end (55), the device (1) comprising a vacuum chamber (10) having an elongated opening (14) extending along a longitudinal axis of the vacuum chamber (10), an evacuation means configured for providing the vacuum chamber (10) with an internal vacuum pressure that is lower than an ambient pressure outside the vacuum chamber (10), means for moving (30) a package (50) relative to the vacuum chamber (10), and a control unit (60) programmed for controlling the means for moving (30) to relatively move a package (50) to be evacuated with respect to the vacuum chamber (10), the package (50) and the means for moving (30) each being arranged with respect to the vacuum chamber (10) so that a main movement direction (40) of packages (50) placed on the means for moving (30) and the longitudinal axis of the vacuum chamber (10) are substantially parallel to one another, the package (50) to be evacuated being positioned so that, during the relative movement of the package (50) with respect to the vacuum chamber (10), a terminal portion (54) of the open end (55) of the package (50) relatively moves within the vacuum chamber (10) and a non-terminal portion (52) of the open end (55) relatively moves outside the vacuum chamber (10), an intermediate portion (53) of the open end (55) passing through and relatively moving along the opening (14), and activating the evacuation means to provide the vacuum chamber (10) with the internal vacuum pressure. A packaging process using the gas evacuation device and a packaging apparatus including the device are also disclosed.